Hesse Lignal, a specialist in intelligent and sustainable coating solutions for the industry and trade sectors, faced the same production optimization challenges as its own customers. The company was looking for a comprehensive solution to improve process efficiency. Dirk Conrad, head of application technology at Hesse Lignal, shares his experience with “smart2i”, the Industry Intelligence solution developed by Hymmen.
THE CHALLENGE
A stable and uninterrupted production process is a key objective for any manufacturing company. Achieving this requires effective process control and quality monitoring. However, companies face multiple challenges in this regard. The increasing complexity of surface treatments due to product diversity makes the process more demanding. Additionally, production lines are often expanded gradually, creating difficulties in integrating new systems smoothly. The lack of data transparency throughout the manufacturing process adds another layer of complexity. At the same time, the industry is dealing with a shortage of skilled labor, which affects operational efficiency. Lastly, there is growing pressure to transition towards a more sustainable production approach.
Until now, no single solution could effectively address all these challenges simultaneously.
A PILOT PROJECT TO TEST “SMART2I”
This led to the idea of launching a pilot project to test “smart2i”, the new industrial software solution developed by Hymmen, a long-standing technology partner of Hesse Lignal.
“I can take the result straight away,” says Dirk Conrad, project manager at Hesse Lignal, speaking at Hymmen’s in-house Tech-Together trade fair. “Transparency in production significantly increases product quality and the overall outcome”.
“Smart2i” enables the digitalization of production processes by automatically collecting all data generated by the machines. This eliminates the need for manual data entry, which is often error-prone and inaccurate. Critical information, such as temperatures, pressures, quantities, and other process parameters, is recorded digitally. This allows production managers to analyze the most frequent causes of machine downtime in real time, understand their systems in detail, and implement preventative measures. As a result, waste has been reduced, and no new quality issues have arisen in production.
KEY ADVANTAGES OF THE SOLUTION
Dirk Conrad was particularly impressed by several aspects of the system. The ability to customize dashboards made it easier to monitor production processes effectively. The integration of all data sources into a single system simplified access to relevant information. Furthermore, combining machine data with quality data provided a more comprehensive view of the production process. Another key benefit was the accessibility of the system from pcs, tablets, and smartphones, ensuring that production status and analytics could be reviewed anytime and anywhere.
At the beginning of the pilot project, a large amount of data had already been mapped and could be integrated into smart2i. However, additional measurements were required to complete the system, which was achieved by incorporating extra sensors. This process was seamless, as various manufacturers of measuring instruments provide the necessary components that can be implemented within “smart2i”. At Hesse Lignal, the newly integrated data included uv power and uv dose, lab values, gloss level, and coating thickness.
Machines and sensors are connected via the “smart2i-connect gateway”, enabling second-by-second data analysis. This significantly simplifies both calibrating the entire process and managing subsequent production operations.
THE RESULTS OF THE TEST PHASE
Hesse Lignal extensively tested the “smart2i” Industry Intelligence solution in its in-house technology center and applied it to a wide range of customer processes. The system not only demonstrated its ability to increase production efficiency, but also significantly contributed to reducing waste and lowering the reject rate by up to 12 percent.
One of the most striking benefits was its ease of use. “All data and information are visualized at the touch of a single button”, notes Conrad.
The platform successfully addresses the initial challenges identified at the start of the project. The complexity of surface treatments caused by product diversity can now be accurately measured using various integrated sensors. Newly added production lines can also be seamlessly incorporated into the system. Data is processed and displayed transparently and in a user-specific manner, whether for the managing director, the plant manager, or the machine operator. The automation of production control serves as a targeted response to the industry-wide shortage of skilled workers, while the enhanced transparency of data allows companies to take concrete steps toward achieving a more sustainable production process.
“We can only recommend smart2i,” concludes Dirk Conrad. “It is a comprehensive system that can be adapted to any type of plant configuration”.
hymmen.com
hesse-lignal.com
